Galvanization 1

Galvanization
Galvanization (or galvanisation) is the process of applying a
protective zinc coating to steel or iron, in order to prevent rusting.
The term is derived from the name of Italian scientist Luigi
Galvani. Although galvanization can be done with electrochemical
and electrodeposition processes, the most common method in
current use is hot-dip galvanization, in which steel parts are
submerged in a bath of molten zinc. In industry, the term GI stands
for galvanized iron, referring to a common galvanized steel used in
many applications such as air ducts and trash cans.

Meanings

Metal protection
In current use, the term refers to the coating of steel or iron with
zinc. This is done to prevent rusting of the ferrous item. The value
of galvanizing stems from the corrosion resistance of zinc, which,
under most service conditions, is considerably greater than that of
iron and steel. The zinc serves as a sacrificial anode, so that it
cathodically protects exposed steel. This means that even if the
coating is scratched or abraded, the exposed steel will still be
protected from corrosion by the remaining zinc - an advantage
absent from paint, enamel, powder coating and other methods. A street lamp in Singapore showing the characteristic
spangle of hot-dip galvanizing.
Galvanizing is also favored as a means of protective coating
because of its low cost, ease of application and comparatively long
maintenance-free service life.

The term galvanizing, while technically referring specifically to the application of zinc coating by the use of a
galvanic cell (also known as electroplating), is also generally understood to include hot-dip zinc coating. The
practical difference is that hot-dip galvanization produces a thick, durable and matte gray coating - electroplated
coatings tend to be thin and brightly reflective. Due to its thinness, the zinc of electroplated coatings is quickly
depleted, making them unsuitable for outdoor applications (except in very dry climates). When combined with
subsequent painting (which slows zinc consumption), electroplating is durable enough to be used in some premium
auto body coatings.

Nonetheless, electroplating is used on its own for many outdoor applications because it is cheaper than hot dip zinc
coating and looks good when new. Another reason not to use hot dip zinc coating is that for bolts and nuts size M10
(US 3/8") or smaller, the thick hot-dipped coating fills in too much of the threads, which reduces strength (because
the dimension of the steel prior to coating must be reduced for the fasteners to fit together). This means that for cars,
bicycles and many other 'light' mechanical products, the alternative to electroplating bolts and nuts is not hot dip zinc
coating but making the bolts and nuts from stainless steel (known by the corrosion grades A4 and A2).
Galvanization 2

History
Originally, "galvanization" was the administration of electric shocks (in the 19th century also termed Faradism, after
Michael Faraday). It stemmed from Galvani's induction of twitches in severed frogs' legs, by his accidental
generation of electricity. Its claims to health benefits have largely been disproved, except for some limited uses in
psychiatry in the form of electroconvulsive therapy (ECT). This archaic sense is the origin of the meaning of
galvanic when meaning "affected/affecting, as if by a shock of electricity; startled".[1] and the metaphorical
"galvanize into action" referring to suddenly stimulating a complacent person or group to take action. Later the word
was used for processes of electrodeposition, which remains a useful and broadly applied technology. But the term
"galvanization" has largely come to be associated with zinc coatings, to the exclusion of other metals.
Galvanic paint, a precursor to hot-dip galvanization, was patented by Stanislas Sorel, of Paris, France in December,
1837.[2]
The earliest known example of galvanizing of iron was found on 17th century Indian armor in the Royal Armouries
Museum collection.[3]

Zinc coatings
Zinc coatings prevent corrosion of the protected metal by forming a physical barrier, and by acting as a sacrificial
anode even if this barrier is damaged. When exposed to the atmosphere, zinc reacts with oxygen to form zinc oxide,
which further reacts with water molecules in the air to form zinc hydroxide. In turn, zinc hydroxide reacts with
carbon dioxide in the atmosphere to yield a thin, impermeable, tenacious and quite insoluble dull gray layer of zinc
carbonate which adheres extremely well to the underlying zinc, so protecting it from further corrosion. This is
similar to the protection afforded to aluminium and stainless steels by their oxide layers.
Hot-dip galvanizing deposits a thick robust layer that may be more than is necessary for the protection of the
underlying metal in some applications. This is the case in automobile bodies, where additional rust proofing paint
will be applied. Here, a thinner form of galvanizing is applied by electroplating, called "electrogalvanization". The
hot-dip process does generally not reduce strength on a measurable scale,[4] with the exception of high-strength
steels (>1100 MPa) where hydrogen embrittlement can become a problem.[5] This is a consideration for the
manufacture of wire rope and other highly-stressed products. The protection provided by this
processWikipedia:Avoid weasel words is insufficient for products that will be constantly exposed to corrosive
materials such as salt water. For these applications, more expensive stainless steel is preferred. Some nails made
today are electro-galvanized.
As noted previously, both mechanisms are often at work in practical applications. For example, the traditional
measure of a coating's effectiveness is resistance to a salt spray. Thin coatings cannot remain intact indefinitely when
subject to surface abrasion, and the galvanic protection offered by zinc can be sharply contrasted to more noble
metals. As an example, a scratched or incomplete coating of chromium actually exacerbates corrosion of the
underlying steel, since it is less electrochemically active than the substrate.
The size of crystallites in galvanized coatings is a visible and aesthetic
feature, known as spangle. By varying the number of particles added
for heterogeneous nucleation and the rate of cooling in a hot-dip
process, the spangle can be adjusted from an apparently uniform
surface (crystallites too small to see with the naked eye) to grains
several centimetres wide. Visible crystallites are rare in other
engineering materials.

Galvanized surface with visible spangle

Galvanization 3

Thermal diffusion galvanizing, a form of Sherardizing, provides a zinc coating on iron or copper based materials
partially similar to hot dip galvanizing, but the final surface that results is different from that yielded with hot-dip
galvanizing in that all of the zinc is alloyed.[6] Zinc is applied in a powder form with "accelerator chemicals"
(generally sand,[] but other chemicals are patented). The parts and the zinc powder are tumbled in a sealed drum
while it is heated to slightly below zinc's melting temperature. The drum must be heated evenly, or complications
will arise. Due to the chemicals added to the zinc powder, the zinc/iron makes an alloy at a lower temperature than
hot dip galvanizing. This process requires generally fewer preparatory cleanings than other methods. The dull-grey
crystal structure formed by the process bonds more strongly with paint, powder coating, and rubber overmolding
processes than other methods. It is a preferred method for coating small, complex-shaped metals, and for smoothing
in rough surfaces on items formed with powder metal.

Eventual corrosion
Although galvanizing will inhibit attack of the underlying steel, rusting
will be inevitable, especially if exposed to the natural acidity of rain.
For example, corrugated iron sheet roofing will start to degrade within
a few years despite the protective action of the zinc coating. Marine
and salty environments also lower the lifetime of galvanized iron
because the high electrical conductivity of sea water increases the rate
of corrosion. Galvanized car frames exemplify this; they corrode much
quicker in cold environments due to road salt. Galvanized steel can last
for many years if other means are maintained, such as paint coatings Rusted corrugated steel roof

and additional sacrificial anodes.

Galvanized piping
In the early 20th century, galvanized piping replaced cast iron and lead in cold-water plumbing. Typically,
galvanized piping rusts from the inside out, building up plaques on the inside of the piping, causing both water
pressure problems and eventual pipe failure. These plaques can flake off, leading to visible impurities in water and a
slight metallic taste. The life expectancy of such piping is about 70 years, but it may vary by region due to impurities
in the water supply and the proximity of electrical grids for which interior piping acts as a pathway (the flow of
electricity can accelerate chemical corrosion). Pipe longevity also depends on the thickness of zinc in the original
galvanization, which ranges on a scale from G40 to G210, and whether the pipe was galvanized on both the inside
and outside, or just the outside. Since World War II, copper and plastic piping has replaced galvanized piping for
interior drinking water service, but galvanized steel pipes are still used in outdoor applications where mechanical
strength is required.
This lends some truth to the urban myth that water purity in outdoor water faucets is lower, but the actual impurities
(iron, zinc, calcium) are harmless. This is not always the case in pre-1986 copper pipe where lead-containing solder
was commonly used. In installations where copper pipe has been fitted to replace a section of corroded galvanized
pipe, a special dielectric fitting called a "union" must be used to join the two types of pipes; otherwise the presence
of water in contact with differing metals creates an electrical current that can cause "galvanic corrosion". In some
amateur installations, the failure to use this special fitting has caused the lead in the solder to leach into the drinking
water. A common location where this occurs is where a home's copper piping connects to a galvanized steel
municipal supply line.
The presence of galvanized piping detracts from the appraised value of housing stock because piping can fail,
increasing the risk of water damage. Galvanized piping will eventually need to be replaced if housing stock is to
outlast a 50 to 70 year life expectancy, and some jurisdictionsWikipedia:Avoid weasel words require galvanized
piping to be replaced before sale. One option to extend the life expectancy of existing galvanized piping is to line it
Galvanization 4

with an epoxy resin.[citation needed]

References
[2] Process for protecting articles made of Iron or Steel from oxidation." (http:/ / books. google. co. uk/ books?id=W8oGAAAAYAAJ&
pg=PA52& dq="Specification+ of+ a+ Patent+ for+ a+ process+ for+ protecting+ articles+ made+ of+ Iron+ or+ Steel+ from+ oxidation. "&
lr=& as_brr=0& as_pt=ALLTYPES) Specification of patent granted to M. Sorel, of Paris, France, December, 1837. Journal of the Franklin
Institute (Philadelphia, Pa.), Published by Pergamon Press, 1838, via Google Book Search.
[3] (http:/ / www. royalarmouries. org/ what-we-do/ research/ analytical-projects/ zinc-coatings-of-indian-plate-and-mail-armour) Summary of
XRF analysis conducted on or about 30 September 1999 by the Royal Armouries Museum in Leeds and written up as part of a thesis by Helen
Bowstead Stallybrass at the Department of Archaeological Sciences, Bradford University.
[4] Industrial Galvanizers: http:/ / www. ingal. com. au/ IGSM/ 28. htm
[5] American Galvanizers Association: http:/ / www. galvanizeit. org/ designing-fabricating/ design-considerations/ steel-selection/
[6] Presentation on Thermal Diffusion Galvanizing: http:/ / www. armycorrosion. com/ past_summits/ summit2009/
09Presentations%5CDay3%5CMosheMoked. pdf

External links
American Galvanizers Association (http://www.galvanizeit.org/)
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